Process and device for manufacturing mother capacitors by helical winding

ABSTRACT

The present invention provides a process and a device for manufacturing superposed mother capacitors comprising the spiral winding of metalized films on a wheel as well as periodic interpositioning of an insert. The position of an interpositioning device is made dependent on the position of the external layer of the winding, and at least a first means is moved from a rear position to a forward position. The first means may carry a second means and the travel paths of the first and second means may be adjusted by cams, more particularly for positioning a cutting device carried by said first means.

This is a continuation of application Ser. No. 457,476, filed Jan. 12,1983, now U.S. Pat. No. 4,494,704.

BACKGROUND OF THE INVENTION

The present invention relates to a process and device for manufacturingmother capacitors by spiral winding.

A process is known, from the SIEMENS patent application No. 2 011 553published on Mar. 6, 1970, for manufacturing laminated capacitors byspiral winding on a roller, with insert layers without capacitive effectinterpositioned between several of the dielectric layers and platelayers which form a block, so that these separating or insert layersdivide the block into several superposed mother capacitors. Then theside edges of the layers are completely covered with a contact metal andfinally the mother capacitors are separated and cut up into individualcapacitors.

The introduction of the insert layer may be made manually. Such anoperation is time-consuming and requires the presence of a trainedoperator.

The present invention relates to a process and a device that do notpresent the above-mentioned drawbacks.

SUMMARY OF THE INVENTION

The invention provides a process for manufacturing superposed mothercapacitors, comprising spiral winding of metalized films on a wheel aswell as periodic interpositioning, after a given number of windingrevolutions, of an insert having a leading edge and a rear edge, whereinan operation is used for making the position of an insertinterpositioning device dependent on the position of the external layerof the winding, and an operation for interposing an insert comprisingthe steps of stopping the wheel, moving the interpositioning device froma rear, so-called rest, position to a forward position for presentingthe insert by its leading edge, again rotating the wheel forinterpositioning of the insert and moving the interpositioning device toits rear position so as to continue the winding of the films.

The operation for interpositioning an insert may comprise an operationfor raising a presser roller of the film for presenting the insertthereunder. It may comprise a step for cutting the insert. Said cuttingmay be accomplished with a length increasing linearly with the radius ofthe external layer of the winding, so that the rear edges of thesuccessive inserts are aligned along a radius of the wheel. Theinterpositioning device may comprise a cutting device and a mobile clipfor feeding the insert, the interpositioning device may comprise camsforming front and rear stops, and the cutting step then uses the stepsof rotating the wheel through a fraction of a turn, stopping the wheelagain, cutting the insert, the interpositioning device being against itsfront stop, and again setting the wheel in rotation, and the profile ofthe cams is chosen so that the insert is cut by the cutting device to alength such that, after winding, the rear edges of the successiveinserts are located along the same radius of the wheel.

The presentation of the insert may be advantageously carried out byovershooting the point where it is tangent to the external layer of thewinding, so that a segment of the insert is nipped by the presser rollerso as to begin the winding.

According to a preferred embodiment, the overshoot is proportional tothe radius of the external layer of the winding, so that the leadingedges of the successive inserts are aligned along a radius of the wheel.The movement of the interpositioning device between the rear positionand the forward position may then consist in moving a first means alonga given path between a rear stop and a front stop, and in extending themovement by a second means carried by the first as far as a front stopformed by a cam so as to provide said proportional movement, the insertbeing advanced by a mobile clip carried by the second means, the mobileclip being for this purpose in a closed position. The movement of theinterpositioning device between the forward position and the rearposition may then consist in moving the second and the first means totheir rear stop while maintaining the mobile clip open.

The invention also relates to a device for manufacturing superposedmother capacitors comprising a device for the spiral winding ofmetalized films on a wheel, as well as a device for periodicallyinterpositioning an insert after a given number of winding revolutions,for implementing the process, characterized in that the periodicinterpositioning device is carried by a mobile compensating device andis capable of moving between a rear, so-called rest, position and aforward position in which the insert is presented at the point where thefilms join the winding, and in that it comprises a sensor detecting theposition of the external layer of the winding on the wheel and controlof the position of the compensating device slaved to the position ofsaid external layer.

It may comprise a roller for pressing the stack and the point where thefilms join the winding is the contact point between the presser rollerand the winding.

According to an advantageous embodiment, the presser roller isassociated with a shaft connected to a device for applying the pressureforce of the roller, and integral with the compensating device, saidsensor is adapted to measure the angular position of said shaft and saidslaved control is arranged to move the compensating device in a givendirection so that said shaft maintains a given angular position. Thesensor may be formed by two photo-electric barriers disposed on eachside of the given angular position of said shaft and the slaved controlis of the all or nothing type.

The device for applying the pressure force may be a stepper motor andsaid sensor a circuit for decoding the angular position of the steppermotor.

The interpositioning device may comprise a first means having a mobileclip for advancing the insert, a cutting device and an insertintroducing device, and a fixed clip may be carried by the frame of thedevice.

According to a preferred embodiment, the interpositioning devicecomprises a first means movable between a forward stop and a rear stop,and carrying a cutting device, as well as a second means movable betweena forward stop and a rear stop. The second means carries a clip foradvancing the insert and an insert introducing device. A fixed clip maybe carried by the frame of the device. The front stop of the secondmeans may be a cam whose angle of slope is chosen so that the leading orinput edge of the successive i,nserts is disposed on the same radius ofthe wheel. The stops of the first means may then be cams whose angle ofslope is chosen so that the insert is cut by the cutting device to alength such that, after winding, the rear edges of the successiveinserts are located along the same radius of the wheel.

At least one of said means may be a slide.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from reading the followingdescription given by way of non limiting example, with reference to theaccompanying drawings in which:

FIGS. 1 to 7 show a device according to one embodiment of the invention,showing the different steps of an insert interpositioning sequence,

FIG. 8a illustrates the calculation of the angles of the cams and FIG.8b is a detail of FIG. 8a, showing the positioning of the wheel 2, and

FIG. 9 shows inserts after interpositioning thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows one embodiment of the device for periodicallyinterpositioning an insert, for spirally winding two films 14 and 15 ona wheel 9. The insert 1 is supplied from a ribbon carried by a reel, notshown. As a variation, the inserts 1 may be pre-cut to desired lengths.Films 14 and 15 are brought to the level of a presser roller 2associated with a device 16 for applying a pressure force, so as topress at all times films 14 and 15 against the preceding turns of thewinding. Films 14 and 15 are moreover delivered at a constant tensionwhich ensures homogeneous winding on wheel 9. The angular position ofshaft 2' (see FIG. 8b) associated with the presser roller is determinedby a measuring, sensor 2", shown schematically in FIG. 8b, which may beformed by two opto-electronic barriers disposed on each side of a givenangular position of arm 2'. According to a preferred embodiment, device16 is a stepper motor applying a constant torque to shaft 2', and theangular position measurement is obtained by decoding the angularposition of the stepper motor. The rotation of wheel 9 is interruptedafter a given number of revolutions, for interpositioning an insert 1 bymeans of an interpositioning device carried by a mobile compensatingdevice, in this case a main slide 3.

The positioning of the main slide 3 is made dependent on the position ofthe external layer of the winding on wheel 9. Since device 16 forapplying a force and the measuring device are carried by the main slide3, this latter is controlled in position along an axis such that theangular position of arm 2' remains constant.

The device for periodically interpositioning an insert carried by themain slide 3 is adapted to move between a rear, so-called rest, positionand a forward position in which the insert 1 is presented at the pointwhere the films join the winding, namely in the case in question at thelevel of presser roller 2. The interpositioning device is formed by afirst means movable between two stops, for example a primary slide 6and, if useful, a secondary means movable between two stops, for examplea secondary slide 7 whose function will be explained in greater detailhereafter. The main slide 3 supports, besides the primary slide 6 andthe secondary slide 7, a fixed clip 19. The primary slide 6 supports thesecondary 7 and a cutting device 12. The secondary slide 7 comprises aninsert guide 10, for guiding the insert 1 when introduced at the levelof presser roller 2, and supports a mobile clip 8.

The main slide 3 is driven by a motor 4 coupled to a screw-nut system 5,and the primary 6 and secondary 7 slides are each driven by a piston andcylinder device, respectively 11 and 13. The primary slide 6 is movablebetween a rear stop 20 and a forward stop 21 integral with the frame 30of the device. These two stops 20, 21 are advantageously formed by acam. A finger 6' carried by slide 6 cooperates to this end with stops 20and 21.

The secondary slide 7 is movable between a rear stop 23 carried by theprimary slide 6 and a forward stop 22 integral with the frame 30 of thedevice. The front stop 22 is formed by a cam. A finger 7' carried byslide 7 cooperates with stop 22 for this.

In FIG. 1 the device for introducing an insert is in the so-called restposition, which allows films 14 and 15 to be wound on wheel 9. Theprimary 6 and secondary 7 slides are against the rear stops,respectively, at 20 and 23. The fixed clip 19 is closed so as to holdthe insert 1 in place. The mobile clip 8 is open. In this rest position,the screwnut system 5 drives the main slide 3 with a translationalmovement so that shaft 2' is maintained permanently horizontal duringwinding of films 14 and 15.

The rear stop 20 of the primary slide is formed by a linear cam carriedby the frame of the device. This cam is inclined so that the primaryslide 6 against the rear stop moves away from wheel 9 when the mainslide 3 moves away from the center of the wheel 9. More specifically,the angle of slope of cams 20 and 21 is chosen to compensate for thedifference in length of the circumference of the outer layer of wheel 9between two positions of rotation of wheel 9 detected by sensors 17 and18. Furthermore, cam 22 contributes to a more positive introduction ofthe insert at the level of roller 2. The introduction of insert 1 isextended beyond the point where insert 1 arrives tangent to the wheel,by a length corresponding to a given angle of rotation of wheel 9, sothat all the leaders of the successive inserts are aligned along thesame radius OB_(o) of wheel 9 (see FIGS. 8a and 9). Compensation of thislength as a function of the diameter of the outer layer is provided bythe linear cam 22. With this arrangement, by disposing roller 2 a littlebeyond the point where insert 1 arrives tangent to the wheel, insert 1is pressed against the wheel at the beginning of winding thereof, aswill be explained hereafter in greater detail. This allows the windingof the insert to be started without slipping.

In FIG. 2, the fixed clip 19 is open and the mobile clip 8 is closed.The presser roller 2 is raised and the drive for the main slide 3 bymotor 4 and the screw-nut system 5 is interrupted. A mark located onwheel 9 is indexed at a position detected by a sensor 17. The primaryslide 6 is then translated (see FIG. 3) towards its forward stop 21 andthe insert 1 is advanced by the mobile clip 8 over a distance equal tothe distance of travel of the primary slide 6. Since the angle of slopeof cams 20 and 21 is the same, this travel distance is constant whateverthe diameter of the external layer of films 14 and 15. The end of insert1 is then located approximately in tangential contact with the outerlayer of films 14 and 15.

The secondary slide 7 is then translated (see FIG. 4) to its front stop22 and insert 1 is consequently advanced by the mobile clip 8 over acomplementary distance which brings its end below roller 2.

In the next phase (see FIG. 5), the presser roller is again lowered andbears then on insert 1 and films 14 and 15, and the translationalcontrol of the main slide 3 is re-established. The mobile clip 8 is thenopen.

Winding of insert 1 on wheel 9 is then carried out. Wheel 9 rotatesthrough an angle 2π-β until its mark is indexed in a position located bysensor 18. When wheel 9 is in this latter position, the fixed clip 19 isclosed and the cutting device 12 carried by the primary slide 6 isactuated.

The secondary slide 7 is then returned to its rear stop 23 (see FIG. 7)while leaving the insert 1 in position since the fixed clip 19 is closedand the mobile clip 8 open. The rest position is resumed with return ofthe primary slide 6 to its rear stop 20 (FIG. 1). Wheel 9 is againrotated and so winds up the remaining insert portion 1 and a new stackof layers of films 14 and 15. It will be readily understood that, sincethe primary slide 6 which carries the cutting device 12 has been broughtback in its travel to the rear stop by a given amount independent of thediameter of the external layers of films 14 and 15, the end of insert 1will project beyond the insert guide 10 by a given amount which isitself constant.

Referring to FIGS. 8a, 8b and 9, the manner in which the angles of thecams are defined will now be described. First of all, the angle of cam22 is defined. Wheel 9 has an external diameter R. The radius R' is themaximum theoretical radius of the wound layers. When the primary slide 6is against its front stop 21, the insert 1 arrives tangent to theexternal layers of the films at a point situated on a segment 00', theextension of a radius CO of wheel 9 with center C. We have CO=R andCO'=R'.00' is perpendicular to the direction of movement of the primaryslide 6.

Primary slide 6 brings then the end of insert 1 to the levelof segment00'. The secondary slide 7 extends this movement by an amount varyingbetween 1₂ and 1'₂ (with 1₂ =OB_(o) and 1'₂ =OB_(n)), as far as asegment B_(O) B_(n) of a radius of wheel 9 forming an angle θ with thepreceding one. Point B_(p) corresponds to the p^(th) insert. If we callα₂ the slope of cam 22 with respect to radius 00', the increase δ 1₂ ininsert length will be equal to δ R tan α₂ where δ R is the increase inthe radius of the outer layer. To compensate for angle θ, δ 1₂ must beequal θδR, from which tan α₂ =θ. The result is that the slope of cam 22with respect to radius OO' will in a first approximation be equal to θ,since θ is small.

As shown in FIG. 8b, the axis XX' parallel to OO', over which the shaftof presser roller 2 moves, is staggered by a distance d from segment OO'on the segment OB_(o) side. When roller 2 is lowered, the p^(th) insert1 is pressed against the outer layers of films 14 and 15 overpractically the whole length of segment OB_(p), which facilitates itssubsequent advancing by wheel 9.

As was described above, with the p^(th) insert 1 introduced as far aspoint B_(p), the wheel is rotated through an angle equal to 2π-β, afterwhich the insert is cut.

In so far as the slope of cams 20 and 21 is concerned, it must be suchthat it compensates for the increase in the circumference correspondingto the rotation of wheel 9 through angle B between cutting and completewinding of the insert 1. Thus, cutting of insert 1 is ensured to alength for alignment of the rear edges (C₁,C₂,C₃, . . . , C_(p), . . . ,C_(a)) thereof after winding (see FIG. 9). Cam 22 has already introduceda correction of length corresponding to an angle θ. The compensationwill then be obtained by compensating for an angle φ=β-θ.

As shown in FIG. 9, the edges B₂,B₂,B₃, . . . ,B_(n) and C₁, C₂,C₃, . .. ,C_(n) inserts 1 are preferably located on two radii formingtherebetween an angle ε so as to allow a cutting tool to passtherethrough for separating, by cross cutting, the stacked mothercapacitors from wheel 9.

Consequently, and to take into account the angular offset, the angle tobe compensated for will then be strictly:

    φ-ε=β-θ-ε

since mark 17 corresponds.

We get δ R tan α₁ =δ1₁ and δ1₁ =(β-θ-ε) δR.

The angle α₁ of cams 20 and 21 (see FIG. 10b) is then determined by :

    tan α.sub.1 =β-θ-ε

where α₁ =Arc tan (α-θ-ε).

The invention is not limited to the embodiment described and shown. Thusthe stops for the slides are cams only if it is desired to compensatefor variations in radius of the stacking of the films. Finally, thesecond slide 7 may be omitted since its function is only to facilitatethe presentation of the leading edge of insert 1.

What is claimed is:
 1. A process for manufacturing mother capacitors separated by an insert to form a block wherein the insert divides the block into at least two superposed mother capacitors, comprising spiral winding of metalized films on a wheel as well as periodic interpositioning, after a given number of winding revolutions, of said insert having an input or leading edge and a rear edge, which process comprises an operation for making the position of an insert interpositioning device dependent on the position of the external layer of the winding, and an insert interpositioning operation comprising the steps of stopping said wheel, moving the interpositioning device from a rear, so-called rest, position to a forward position for presenting the insert by its leading edge, setting the wheel again in rotation so as to interposition said insert, moving the interpositioning device from its forward position to its rear position so as to continue winding of the films, and cutting said insert.
 2. The process as claimed in claim 1, wherein said insert interpositioning operation comprises raising a roller pressing on said films for presenting said insert thereunder.
 3. The process as claimed in claim 1, wherein said step of cutting said insert comprises selecting a length of insert to be cut, which length linearly increases with the radius of the external layer of the winding so that the rear edges of the successive inserts are aligned along a radius of said wheel.
 4. The process as claimed in claim 3, wherein said interpositioning device a cutting device, a mobile clip for advancing said insert which is closed during the movement of the interpositioning device to the forward position, and cams forming a front and rear stop, and the cutting step comprises:rotating said wheel by a fraction of a revolution, again stopping said wheel, cutting said insert, the interpositioning device being against its front stop, and again rotating the wheel; and wherein the profile of said cams is chosen so that said insert is cut by the cutting device to a length such that, after winding, the rear edges of the successive inserts are located along the same radius of said wheel.
 5. The process as claimed in claim 4, wherein the presenting of said insert comprises overshooting of the point where the inert is tangent to the external layer of the winding, so that a segment of the insert is pressed by a presser roller for starting the winding.
 6. The process as claimed in claim 5, comprising:selecting an amount of overshooting proportional to the radius of the external layer of the winding, so that the leading edges of the successive inserts are aligned along a radius of said wheel.
 7. The process as claimed in claim 6, wherein the step of moving said interpositioning device between the rear position and the forward position comprises:moving a first means over a given distance between said rear stop and said front stop, and extending the movement by a second means carried by the first means as far as the front stop, said insert being advanced by a mobile clip carried by the second means, the mobile clip being closed for this purpose.
 8. The process as claimed in claim 7, wherein the moving of said interpositioning device between the forward position and the rear position comprises:moving the second and the first means towards their rear stop while maintaining the mobile clip open.
 9. A device for manufacturing mother capacitors separated by an insert to form a block wherein the insert divides the block into at least two superposed mother capacitors, comprising a device for spirally winding metalized films on a wheel, as well as a device for periodically interpositioning said insert after a given number of winding revolutions, wherein the periodic interpositioning device comprises a mobile compensating device which is movable between a rear, so-called rest, position and a forward position in which the insert is presented at the point where the films join the winding, and further comprising a sensor for detecting the position of the external layer of the winding on the wheel, a control device responsive to said sensor for controlling the position of the compensating device in dependence on the position of said external layer, and means for cutting said insert.
 10. The device as claimed in claim 9, further comprising a roller for pressing the metalized films and wherein the point where the metalized films join the winding is the point of contact between said presser roller and said winding.
 11. The device as claimed in claim 10, wherein said presser roller is coupled to a shaft connected to a device for applying a pressure force to the roller, integral with the compensating device, said sensor measuring the angular position of said shaft and said control device including means for moving said compensating device so that said shaft maintains a given angular position.
 12. The device as claimed in claim 11, wherein said sensor is formed by two photo-electric barriers disposed on each side of said given angular position of said shaft.
 13. The device as claimed in claim 11, wherein said device for applying the pressure force is a stepper motor and said sensor is a circuit for decoding the angular position of said stepper motor.
 14. The device as claimed in claim 9, comprising a frame which carries a fixed clip.
 15. The device as claimed in claim 9, wherein said interpositioning device comprises:a mobile clip for advancing said insert; and a first means carrying said mobile clip.
 16. The device as claimed in claim 9, wherein said interpositioning device comprises:a mobile clip for advancing said insert; an insert introducing device; a first means movable between a forward stop and a rear stop and carrying said cutting means; and a second means movable between a forward stop and a rear stop, said second means carrying said mobile clip for advancing said insert as well as said insert introducing device.
 17. The device as claimed in claim 16, wherein the forward stop limiting movement of said second means is a cam whose profile is chosen so as to position the leading edges of the successive inserts on the same radius of said wheel.
 18. The device as claimed in claim 17, wherein said cam is a slide.
 19. The device as claimed in claim 16, wherein the stops between which said first means is movable comprise first and second cams which have profiles chosen so that said insert is cut by the cutting means to a length such that, after winding, the rear edges of the successive inserts are located along the same radius of the wheel.
 20. The device as claimed in claim 19, wherein at least one of said first and second cams is slide.
 21. The device as claimed in claim 17, wherein the stops between said first means is movable comprise cams having profiles chosen so that said insert is cut by the cutting device to a length such that, after winding, the rear edges of the successive inserts are located along the same radius of the wheel.
 22. The device as claimed in claim 21, wherein at least one of the cams of said first means is a slide. 